Electric vehicle charging handle, light pipe therefor, and associated light visibility enhancing method

ABSTRACT

A light pipe is for an EV charging handle. The EV charging handle includes a housing having a thru hole, and a light source coupled to the housing. The light pipe includes a body structured to be coupled to the light source in order to transmit light from the light source through the thru hole of the housing, the body having a first side portion having a first interior surface having a first surface roughness, and a second side portion extending from the first side portion, the second side portion having a second interior surface having a second surface roughness greater than the first surface roughness in order to increase a visibility range with which the light is transmitted through the thru hole of the housing.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from and claims the benefit of U.S.patent application Ser. No. 15/412,261, filed Jan. 23, 2017, andentitled “ELECTRIC VEHICLE CHARGING HANDLE, LIGHT PIPE THEREFOR, ANDASSOCIATED LIGHT VISIBILITY ENHANCING METHOD.”

BACKGROUND Field

The disclosed concept pertains generally to electric vehicle (EV)charging handles. The disclosed concept also pertains to light pipes forEV charging handles. The disclosed concept further pertains to methodsof enhancing light visibility.

Background Information

With the development of EV technology, the number of EVs is growingrapidly, and electric vehicle charging stations, similar to gasstations, have become popular. An EV charging station, also called anelectric recharging point, charging point, and EVSE (Electric VehicleSupply Equipment), is an element in an infrastructure that supplieselectric energy for the recharging of electric vehicles, plug-in hybridelectric-gasoline vehicles, or semi-static and mobile electrical unitssuch as exhibition stands. An EV charging station is a device thatsafely allows electricity to flow. EV charging stations generallycontain a completely separate and unique box along with a connected EVcharging handle.

Known EV charging handles include charging status indicator lights andlight pipes coupled to the indicator lights. The light pipes transmitlight from an interior of the charging handle to an exterior thereof inorder to provide an indication to a user of the charging status. Knownlight pipes are limited in that the user can only see the emitted lightwithin a relatively narrow visibility range.

There is, therefore, room for improvement in EV charging handles and inlight pipes therefor.

There is also room for improvement in methods of enhancing lightvisibility.

SUMMARY

These needs and others are met by embodiments of the disclosed concept,which are directed to an improved EV charging handle, light pipetherefor, and associated light visibility enhancing method.

In accordance with one aspect of the disclosed concept, a light pipe isprovided for an EV charging handle. The EV charging handle includes ahousing having a thru hole, and a light source coupled to the housing.The light pipe includes a body structured to be coupled to the lightsource in order to transmit light from the light source through the thruhole of the housing, the body having a first side portion having a firstinterior surface having a first surface roughness, and a second sideportion extending from the first side portion, the second side portionhaving a second interior surface having a second surface roughnessgreater than the first surface roughness in order to increase avisibility range with which the light is transmitted through the thruhole of the housing.

As another aspect of the disclosed concept, an EV charging handleincluding the aforementioned light pipe is provided.

As another aspect of the disclosed concept, a method of enhancing lightvisibility includes the steps of providing a housing having a thru hole;providing a light source coupled to the housing; providing a light pipecomprising a body coupled to the light source, the body comprising afirst side portion having a first interior surface having a firstsurface roughness, and a second side portion extending from the firstside portion, the second side portion having a second interior surfacehaving a second surface roughness greater than the first surfaceroughness; energizing the light source in order to transmit light;reflecting the light off of the first interior surface; and reflectingthe light off of the second interior surface in order to increase avisibility range with which the light is transmitted through the thruhole of the housing.

BRIEF DESCRIPTION OF THE DRAWINGS

A full understanding of the disclosed concept can be gained from thefollowing description of the preferred embodiments when read inconjunction with the accompanying drawings in which:

FIG. 1 is a side elevation view of an EV charging handle and a portionof a light pipe therefor, in accordance with a non-limiting embodimentof the disclosed concept;

FIG. 2 is another side elevation view of the EV charging handle andlight pipe therefor of FIG. 1, shown with a portion of the housingremoved in order to see hidden structures;

FIG. 3 is a top plan view of the EV charging handle and light pipetherefor of FIG. 1;

FIG. 4 is a front view of the EV charging handle and light pipe thereforof FIG. 3;

FIG. 5 is a rear view of the EV charging handle and light pipe thereforof FIG. 4;

FIG. 6 is a front view of a light pipe for the EV charging handle ofFIG. 5, shown with a light source and light rays in simplified form;

FIG. 7 is a left side elevation view of the light pipe of FIG. 6;

FIG. 8 is a right side elevation view of the light pipe of FIG. 6; and

FIG. 9 is a simplified exaggerated view of portion of an interiorsurface of the light pipe of FIG. 6.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As employed herein, the term “number” shall mean one or an integergreater than one (i.e., a plurality).

As employed herein, the statement that two or more parts are “connected”or “coupled” together shall mean that the parts are joined togethereither directly or joined through one or more intermediate parts.

FIGS. 1-5 show an EV charging handle 2, in accordance with anon-limiting embodiment of the disclosed concept. The example EVcharging handle 2 includes a housing 4, a printed circuit board 12(shown in FIG. 2) coupled to and located internal with respect to thehousing 4, a number of light sources (three of six example lightemitting diodes 14,16,18 are shown in FIG. 2) electrically connected tothe printed circuit board 12, and a corresponding number of novel lightpipes 50,60,70,80,90,100 each having a body coupled to one of the lightemitting diodes 14,16,18. Each of the light emitting diodes 14,16,18 issimilarly cooperable with a corresponding one of the light pipes50,60,70,80,90,100, although only some of the light emitting diodes14,16,18 are explicitly shown and described herein.

The housing 4 has a number of edge portions (three of six edge portions6,8,10 are indicated in FIG. 1) that each define a thru hole. The lightpipes 50,60,70,80,90,100 transmit light from the light emitting diodes14,16,18 through the thru holes defined by the edge portions 6,8,10 inorder to provide an indication of charging status to a user. That is, auser can view which of the light pipes 50,60,70,80,90,100 areilluminated in order to determine the charging status (e.g., withoutlimitation, a charging state, an off state, an error state, etc.).Furthermore, the light pipes 50,60,70,80,90,100 each generally extendfrom a corresponding one of the light emitting diodes 14,16,18 to acorresponding one of the edge portions 6,8,10 and are located internalwith respect to the housing 4. As will be discussed in greater detailbelow, the light pipes 50,60,70,80,90,100 are advantageously structuredso as to increase a visibility range (i.e., a visibility range 81 shownin FIGS. 5 and 6) with which light is transmitted through the thru holesdefined by the edge portions 6,8,10.

FIGS. 6-8 show different views of the light pipe 80. In one exampleembodiment, each of the light pipes 50,60,70,90,100 is structuredsubstantially the same as the light pipe 80. However, for ease ofillustration and economy of disclosure, only the light pipe 80 will bediscussed in greater detail herein. The body of the light pipe 80 ispreferably a unitary component made from a single piece of material(e.g., without limitation, an injection molded component made from asuitable thermoplastic material). The body of the light pipe 80 includesa first side portion 82, a second side portion 84 extending from andbeing perpendicular to the first side portion 82, a third side portion86 extending from and being perpendicular to the second side portion 84,and a fourth side portion 88 connecting the first side portion 82 to thethird side portion 86. Although the disclosed concept is being describedherein in association with side portions 82,84,86,88 perpendicular toeach other, it will be appreciated that a similar suitable alternativelight pipe (not shown) may have any suitable alternative geometry and/ororientation of side portions, without departing from the scope of thedisclosed concept. The side portions 82,84,86,88 each have respectiveinterior surfaces 83,85,87,89 for reflecting light. See, for example,light rays shown in phantom line drawing in FIG. 6, which are generatedby an example light emitting diode 22 (shown in dashed line drawing) andwhich reflect off of the interior surfaces 83,85,87,89.

It will be appreciated with reference to FIG. 6 that the reflection ofthe light rays off of the interior surface 89 is specular reflection(i.e., mirror reflection) and the reflection of the light rays off ofthe interior surface 85 is diffuse reflection. In one exampleembodiment, the reflection of the light rays off of the interiorsurfaces 83,87 is also specular reflection (i.e., mirror reflection).Stated differently, light incident upon the interior surfaces 83,87,89reflects at the same angle, whereas light incident upon the interiorsurface 85 reflects in a broad range of directions. In order to achievethis reflective attribute of the interior surface 85, a surfaceroughness of the interior surface 85 is greater than a surface roughnessof the interior surfaces 83,87,89. In accordance with the disclosedconcept, it has been discovered that by making the surface roughness ofthe interior surfaces 83,87,89 R_(a)<0.8 micrometers and the surfaceroughness of the interior surface 85 R_(a)>0.8 micrometers, thereflection of light off of the interior surfaces 83,87,89 will bespecular reflection, and the reflection of the light off of the interiorsurface will be diffuse reflection.

An enlarged, exaggerated and simplified view of the interior surface 85is shown in FIG. 9. As shown, the interior surface 85 has a centrallydisposed plane 110 and a plurality of peak portions (four example peakportions 112,114,116,118 are indicated in FIG. 9) each spaced a distance113,115,117,119 from the centrally disposed plane 110. The average ofthe distances 113,115,117,119 of the peak portions 112,114,116,118 fromthe centrally disposed plane 110 is greater than 0.8 micrometers (i.e.,a relatively rough surface finish, as compared to the interior surfaces83,87,89). It will be appreciated that an average of the distances ofthe peak portions of the respective interior surfaces 83,87,89 fromrespective centrally disposed planes is less than 0.8 micrometers (i.e.,a relatively smooth surface finish as compared to the interior surface85).

Referring again to FIGS. 5 and 6, the visibility range 81 with whichlight exits the housing 4 is relatively large, as compared with a priorart EV charging handle (not shown) in which all of the light pipes haveinterior surfaces with surface roughnesses of R_(a)<0.8 micrometers.Stated differently, the reflection of the light from the light emittingdiodes off of all of the interior surfaces of the light pipes of priorart EV charging handles (not shown) is specular reflection, whereas thedisclosed concept advantageously employs with the interior surface 85 asurface roughness of R_(a)>0.8 micrometers in order to provide fordiffuse reflection, an attribute of the EV charging handle 2 which hasbeen discovered to provide for the increased visibility range 81. Thatis, the surface roughness of the interior surface 85 is greater than thesurface roughness of the interior surfaces 83,87,89 in order to increasethe visibility range with which the light is transmitted through thethru holes defined by the edge portions 6,8,10 (FIG. 1). Morespecifically, the increased surface roughness of the interior surface 85results in many light rays reflecting at larger and smaller angles offof the interior surface 85 (i.e., normal lines on the interior surface85 will not be parallel to each other, resulting in greater and smallerangles of reflection for the reflected light rays). As such, lightemitted by the light emitting diodes 14,16,18 (FIG. 2),22 (FIG. 6) isable to more easily be seen by a user. For example, a user positioned ata relative observation point external the housing 4 such as, for exampleand without limitation, the relative observation point generallyindicated by reference 20 in FIG. 1, will see the light transmitted overthe relatively large visibility range 81 (see FIG. 5, depicting the EVcharging handle 20 as seen from the relative observation point 20 (FIG.1)).

In the exemplary embodiment, the only interior surface of the light pipe80 with a surface roughness of R_(a)>0.8 micrometers is the interiorsurface 85 because by employing with the interior surface 85 diffusereflection, a portion of light reflecting off of the interior surface 85will not be irradiated out of the light pipe 80 through the thru hole ofthe housing 4. However, it will be appreciated that in a suitablealternative light pipe (not shown), multiple surfaces may surfaceroughneses of R_(a)>0.8 micrometers, without departing from the scope ofthe disclosed concept. Additionally, although the disclosed concept hasbeen described herein in association with the light pipes50,60,70,80,90,100 in the EV charging handle 2, similar suitablealternative light pipes (not shown) may be employed in other devicesand/or assemblies besides the EV charging handle 2, without departingfrom the scope of the disclosed concept.

It will be appreciated that a method of enhancing light visibilityincludes the steps of providing the housing 4 having a thru hole,providing a light source 14,16,18,22 coupled to the housing 4, providinga light pipe 50,60,70,80,90,100, energizing the light source 14,16,18,22in order to transmit light, reflecting the light off of the interiorsurfaces 83,87,89, and reflecting the light off of the interior surface85 in order to increase a visibility range 81 with which the light istransmitted through the thru hole of the housing 4. It will further beappreciated that the step of reflecting the light off of the interiorsurfaces 83,87,89 further includes specular reflection, and the step ofreflecting the light off of the interior surface 85 further includesdiffuse reflection.

Accordingly, it will be appreciated that the disclosed concept providesfor an improved (e.g., without limitation, able to transmit light over arelatively large visibility range) EV charging handle 2, light pipe50,60,70,80,90,100 therefor and associated light visibility enhancingmethod, in which an interior surface 85 of a light pipe has a greatersurface roughness than other interior surfaces 83,87,89.

While specific embodiments of the disclosed concept have been describedin detail, it will be appreciated by those skilled in the art thatvarious modifications and alternatives to those details could bedeveloped in light of the overall teachings of the disclosure.Accordingly, the particular arrangements disclosed are meant to beillustrative only and not limiting as to the scope of the disclosedconcept which is to be given the full breadth of the claims appended andany and all equivalents thereof.

What is claimed is:
 1. A method of enhancing light visibility comprisingthe steps of: providing a housing having a thru hole; providing a lightsource coupled to said housing; providing a light pipe comprising a bodycoupled to said light source, said body comprising a first side portionhaving a first interior surface having a first surface roughness, and asecond side portion extending from said first side portion, said secondside portion having a second interior surface having a second surfaceroughness greater than the first surface roughness; energizing saidlight source in order to transmit light; reflecting the light off of thefirst interior surface; and reflecting the light off of the secondinterior surface in order to increase a visibility range with which thelight is transmitted through the thru hole of said housing.
 2. Themethod of claim 1 wherein the step of reflecting the light off of thefirst interior surface further comprises specular reflection.
 3. Themethod of claim 2 wherein the step of reflecting the light off of thesecond interior surface further comprises diffuse reflection.
 4. Themethod of claim 3 wherein the first interior surface and the secondinterior surface each have a centrally disposed plane and a plurality ofpeak portions each spaced a distance from the centrally disposed plane;and wherein the average of the distances of the peak portions from thecentrally disposed plane of the first interior surface is less than 0.8micrometers; and wherein the average of the distances of the peakportions from the centrally disposed plane of the second interiorsurface is greater than 0.8 micrometers.
 5. The method of claim 1wherein the first interior surface and the second interior surface eachhave a centrally disposed plane and a plurality of peak portions eachspaced a distance from the centrally disposed plane; and wherein theaverage of the distances of the peak portions from the centrallydisposed plane of the first interior surface is less than 0.8micrometers.
 6. The method of claim 5 wherein the average of thedistances of the peak portions from the centrally disposed plane of thesecond interior surface is greater than 0.8 micrometers.
 7. The methodof claim 1 wherein the second side portion is disposed perpendicular tothe first side portion.
 8. The method of claim 7 wherein said bodyfurther comprises a third side portion extending from and being disposedperpendicular to said second side portion; and wherein said third sideportion has a third interior surface having a third surface roughnessless than the second surface roughness.
 9. The method of claim 1 whereinsaid body is a unitary component made from a single piece of material.10. The method of claim 1 wherein the second surface roughness isgreater than the first surface roughness in order to increase thevisibility range with which the light is transmitted through the thruhole of said housing when the light is viewed from a relativeobservation point external said housing.
 11. The method of claim 1wherein said housing has an edge portion defining the thru hole; andwherein said light pipe generally extends from said light source to theedge portion.
 12. The method of claim 11 wherein said light pipe isdisposed internal with respect to said housing.